HYDRAULIC SYSTEMS: OPERATION & TROUBLESHOOTING …

1 Identify HYDRAULIC systems components Describe essential HYDRAULIC terms and understand their keyapplications Recognise the impact HYDRAULIC fluids have on components Describe the correct OPERATION , control sequences and proceduresfor the safe OPERATION of various simple HYDRAULIC systems Initiate an effective inspection and maintenance program Minimise forced outages and prevent serious damage to hydraulicequipment Explain the latest technologies available for electro hydraulicsystems Plant Engineers OPERATION , Maintenance, Inspection and Repair Managers.

2 Supervisors and Engineers Mechanical Engineers Design Engineers Consulting Engineers Plant operations and Maintenance Personnel Consulting Engineers Process Technicians Mechanical TechniciansPracticalHYDRAULIC SYSTEMS: OPERATION &TROUBLESHOOTINGfor Engineers & TechniciansYOU WILL LEARN HOW TO:WHO SHOULD SAVE over 50% byhaving an IDC workshoppresented at yourpremises. Customise the training to YOUR workplace. Have the trainingdelivered when andwhere you need us for a TWOPRESSURE CONTROL VALVES Relief valves (Pressure regulating &Emergency relief) Meaning of Surge Pressure Sequence Valves Counterbalance Valves Pressure reducing Valves Unloading ValvesFLOW CONTROL VALVES Classification (Non-Pressure Compensated& Pressure Compensated) Location of Flow Control Valve (Meter-in,Meter-out & Bleed-off circuits)

3 ELECTRO- HYDRAULIC SYSTEMS Proportional Solenoid Proportional Valves (Direction control, Flowcontrol & Pressure control Valves) Servo Valves (Direction & Pressure ServoValves, Single Stage & Multi Stage ServoValves) Use of Transducers in HYDRAULIC SystemsHYDRAULIC ACCESSORIESR eservoirs(Pressure & Non pressure types) Need for Breather & Baffle plates Role of HYDRAULIC oil tank in heat dissipationAccumulators Function & Types (Dead weight, Spring load& Hydro-Pneumatic) Accumulator sizing Application of Accumulators in hydrauliccircuitsHeat Exchangers Function & Types ( Air Cooled & WaterCooled)

4 HYDRAULIC Pipes & Hoses Pipe specification & materials Pipe fittings Recommended oil speeds for selecting pipesizes Construction of Hoses Reinforcement & cover variations Criteria for Hose selection Sizing of Hoses Maintenance of pipes & HosesHYDRAULIC FLUIDS Cavitation Aeration Locations of Filters & Strainers Filter Terminology Measurement of contamination levels APPLICATION OF HYDRAULIC CIRCUITS Symbols of HYDRAULIC components Need for check Valve in HYDRAULIC circuits Regenerative circuit Flow equalizer Counterbalance circuit Pre fill & Compression relief circuit Decompression circuit Circuits of Open center, Closed center,Tandem center & Indirect control HYDRAULIC circuits of various machinesTROUBLESHOOTING HYDRAULICSYSTEMS Flow chart analysis of HYDRAULIC circuits MaintenanceDAY ONEINTRODUCTION TO HYDRAULICS Origin of Hydraulics & classificationFUNDAMENTALS Force, Work, Power, Energy, Mass, Weight,Torque, Density.

5 Specific gravity & SpecificweightPRESSURE & FLOW Definition & units of pressure measurement Pascal's law & applications Pressure-Force relationship Fluid flow/ Discharge Steady & Unsteady flows Bernoulli's principle Laminar & Turbulent flows Pressure Flow relationshipHYDRAULIC PUMPS Principles of Pump OPERATION Classification (Positive & Non-Positivedisplacement) Gear Pump Vane Pump (Variable volume & Pressurecompensated Variable volume pumps) Piston Pump (Axial/Inline, Bent axis, Radial,Variable volume, Pressure compensated &over center axial pumps) Gerotor Pump Rating of Pumps Pressure, Flow & Efficiencies of PumpsHYDRAULIC MOTORS Principle of motor OPERATION Classification (Rotating & Piston type) Gear Motors Vane Motors Piston motors Difference between HYDRAULIC motors & HYDRAULIC pumps Specification of HYDRAULIC motors Efficiency of HYDRAULIC motors Motor SlippageHYDRAULIC CYLINDERS Classification (Single & Double acting)

6 Construction of Cylinders Cylinder Mounting Seals Cylinder design checklist Common Cylinder problemsCONTROL VALVES Purpose Classification (Direction, Pressure & Flowcontrol Valves) Valve symbolsDIRECTION CONTROL VALVES Poppet Valve Check Valve Spool Valve (Rotary & Sliding Valves) Direct & Indirect operated Valves Valve actuation methods (Manual, electrical,pilot, pneumatic, Electro- HYDRAULIC & Electro-pneumatic) 2, 3 & 4 way Direction control Valves Positive & negative overlapping Center Conditions (Open center, Closedcenter, Tandem center & Float centerValves)

7 THE PROGRAMW hatever your HYDRAULIC applications, you canincrease your knowledge of the fundamentals,improve your maintenance programs and becomean excellent troubleshooter of problems in thisarea by attending this information packed of all major components are brought tothe sessions to visually demonstrate thecomponents' construction and an understanding of "How" it worksleads to an understanding of how and why it views of the equipment are given togive you as realistic a view of HYDRAULIC systemsas Hydraulics workshop is a highly practical.

8 Comprehensive and interactive two-day will have an opportunity to discussHydraulic Systems construction,design-applications, operations , maintenance andmanagement issues and be provided with themost up-to-date information and Best Practice in dealing with the subject. Towards the end ofthe workshop, you will have developed the skillsand ability to recognise and solve hydraulicproblems in a structured and confident Fundamental knowledge of basic mechanicalplant and OPERATION WORKSHOPWORKSHOP OBJECTIVESA fter attending this highly practical two-dayworkshop you will be able to.

9 Work with basic HYDRAULIC components Understand how basic HYDRAULIC componentsfunction in a HYDRAULIC circuit Read HYDRAULIC schematics Work safely with HYDRAULIC components andsystems Troubleshoot simple hydraulics problems Apply a simple preventative maintenanceprogram to lengthen HYDRAULIC components life Make simple repairs to HYDRAULIC systems